Visit http://www.esabna.com/ for more information about our products.
Building a BBQ
Jeff Heagey is the Stainless Steel Product Manager for ESAB located in Hanover, PA. This is his story about building a backyard BBQ Smoker.
Winters in Pennsylvania can be long, cold and wet. With ample time on my hands, I went to work designing and constructing a 'BBQ smoker'. Thus far, many have enjoyed the fruits of my effort. The complete story can be told from the design to the workmanship that went into constructing this one-of-a-kind BBQ smoker.
Since I knew little about the finer features and principles behind this most marvelous piece of equipment, I decided to travel the "outdoor and camping show" circuit. In addition, various web-based resources gradually gave me the ideas I needed to construct such a unit. Finalizing my plans took several revisions and modifications. The final assurance came when I constructed a 3-D model of the very unit I was attempting to build.
Sourcing the materials was a time consuming task. Prices of material ranged from the ridiculous to the affordable. As I collected all the necessary materials which included both carbon and stainless steel, I began to realize that somehow this would all come together as planned.
One of the best recommendations which came from my colleague Dan Spackman was his introduction to Scade Salvage Metals. Here I quickly recognized the value of shopping. As I collected the vast assortment of steel shapes my creative juices came alive.
Materials List:
7 – 4 in. x 8 in. x 1/8 in C.S (plate)
2 – 4 in. x 4 in. x 5/8 in S.S. (mesh)
15 – ¼ in. x ¼ in. x 8 in. C.S. (angle)
8 – 1-1/2 in. x 1-1/2 in. x 8 in. C.S. (angle)
1 – 2 in. x 40 in. S.S. (rod)
1 - 4 in. round thermometer
1 – 8 in. x 30 in. S.S. shelf
12 – 5/8 in. hex-bolts & nuts
Assorted hardware (handles, hinges, brackets. etc.)
Cast iron burner with copper tubing, fittings and supports
High temperature caulking
After several minor structural design changes I was ready to commence fabrication. Thanks to ESAB-Hanover, space was provided for welding, cutting and grinding. Fabricating a 70 in. high, 24 in. deep and 40 in. wide box requires a unique understanding of design and construction.
Large carbon steel plates were plasma cut with an ESAB HandyPlasma® 550 plasma cutter. The quality of the cut and the ease of operation made for little touch up rework. Cutting door openings and precision located flue-ways were done with little effort. The biggest challenge in cutting came when the 5/8 in. stainless grading had to be sized for shelving. The grating would later become the surface for 3 sliding shelves.
Once all the steel was cut to size, fabrication began. For this we chose the MultiMaster® 260, multiprocessing power supplier with it’s integrated wire feeder. Later, as I began to discover, this became the most universal tool used in this fabrication project.
Cutting, fitting, welding and grinding took a ‘first rate team’. For this I called on some of our talented people that included Bob Rebert, Jerry Doherty, Jerry Mathison, Jeff Roscoe, Chris Cline and others for which I am equally thankful. Fabrication took several weeks to complete.
Metal such as this is not difficult to work with but having a vision an understanding of how so many pieces of plate, angle and meshing came together excited me. Although a bit of bruit force was occasionally needed to keep the many pieces aligned the team assembled willingly accepted the challenge.
The joining of all carbon steel was done with Spoolarc 87 (ER70S-7). The higher manganese and silicon content of the wire made the clean-up easier and provided a good cosmetic finish. The performance of the wire and the ease of use made this easier than expected. The versatility of the MIG process along with its mechanical properties proved sufficient for this project. Welding was done in all positions, including vertical up, down and overhead. In a short time both the flue box as well as the fire box as completely assembled and continuously welded. This 2-part construction proved to be a wise choice when it came to moving the entire unit to its final location.
During the fabrication both carbon and stainless was welded to itself as well as to each other. In all, the GMAW, SMAW, GTAW processes were utilized. Stainless mesh grates measuring 5/8 in. round were plasma cut and fitted to carbon steel ¼ in. x ¼ in. angle iron. Each rectangular shaped shelf frame measured 27 in. x 22 in. x ¼ in. All stainless steel mesh grates was attached to the angle iron frame with Arcaloy 309L-16 3/32 in. electrode. All other stainless welding was done with GTAW process of a similar analysis.
In addition to the main structure, other assorted weldments were necessary, those included the sliding shelf supports and door stops. Attachment brackets on opposite sides of the flue were used to support a 2 in. round stainless rod. This will serve the purpose of hanging meat inside the smoker. Individual meat hanger hooks were formed from 5 mm nickel steel rod. In addition, a propane line feeds gas to a cast iron burner attached below the bottom sliding shelf.
Transporting this 500 lb, 2-piece unit could not have been possible without the help of many strong individuals. Once moved, the next step was to paint the entire outside of the unit. Experience tells me that an air-supplied power sprayer emits an excessive amount of over-spray. As a result, I decided to construct a plastic, ceiling to floor curtain, surrounding the smoker unit. After the third coat of black high temperature stove paint was applied I was convinced that the newly pained metal could withstand the Pennsylvania weather.
As the time approached to relocate this 500 lb beast, our excitement grew. Once in place, the 2 separate units were attached together. Twelve pre-drilled holes were aligned between the 2 units and connected with bolt fasteners. Connected together, as a single unit, there was no moving this structure once in place.
The smoker resides as the center piece of my newly constructed outdoor kitchen. In a space once designed for a garden this area has now been transformed into an outdoor kitchen. Equipped with running water, 110 V power and shaded wood framed pergala, the entire area is protected from the rain and sun.
The kitchen area was designed to be a working area providing such conveniences as a built-in stainless steel cooler/icebox, stainless lined fryer pit and double set of stainless steel sink drains. All features making this area suitable for a BBQ any time.
A project of this magnitude takes some engineering expertise, adequate man-power, the proper tools and lots of imagination. Without the help of so many friends, my Dad, Charlie and other supporters, a project of this magnitude would not have been possible. ESAB equipment, filler metals and human resources made this task possible.
Whether making beef brisquette, baby back ribs or pork shoulders, this unit is capable of heating with wood, charcoal or with LP. As one observer so accurately put it, “this is a real piece of work”.
What started out as a backyard water garden project quickly changed? The idea of a smoker has both a social benefit as well as nutritional value. As my son, Patrick so adequately stated, "Dad this is awesome". So the next time your in Hanover stop by, your never know what might be smokin'.
Jeff can be reached for questions by email.
Winters in Pennsylvania can be long, cold and wet. With ample time on my hands, I went to work designing and constructing a 'BBQ smoker'. Thus far, many have enjoyed the fruits of my effort. The complete story can be told from the design to the workmanship that went into constructing this one-of-a-kind BBQ smoker.
Since I knew little about the finer features and principles behind this most marvelous piece of equipment, I decided to travel the "outdoor and camping show" circuit. In addition, various web-based resources gradually gave me the ideas I needed to construct such a unit. Finalizing my plans took several revisions and modifications. The final assurance came when I constructed a 3-D model of the very unit I was attempting to build.
Sourcing the materials was a time consuming task. Prices of material ranged from the ridiculous to the affordable. As I collected all the necessary materials which included both carbon and stainless steel, I began to realize that somehow this would all come together as planned.
One of the best recommendations which came from my colleague Dan Spackman was his introduction to Scade Salvage Metals. Here I quickly recognized the value of shopping. As I collected the vast assortment of steel shapes my creative juices came alive.
Materials List:
7 – 4 in. x 8 in. x 1/8 in C.S (plate)
2 – 4 in. x 4 in. x 5/8 in S.S. (mesh)
15 – ¼ in. x ¼ in. x 8 in. C.S. (angle)
8 – 1-1/2 in. x 1-1/2 in. x 8 in. C.S. (angle)
1 – 2 in. x 40 in. S.S. (rod)
1 - 4 in. round thermometer
1 – 8 in. x 30 in. S.S. shelf
12 – 5/8 in. hex-bolts & nuts
Assorted hardware (handles, hinges, brackets. etc.)
Cast iron burner with copper tubing, fittings and supports
High temperature caulking
After several minor structural design changes I was ready to commence fabrication. Thanks to ESAB-Hanover, space was provided for welding, cutting and grinding. Fabricating a 70 in. high, 24 in. deep and 40 in. wide box requires a unique understanding of design and construction.
Large carbon steel plates were plasma cut with an ESAB HandyPlasma® 550 plasma cutter. The quality of the cut and the ease of operation made for little touch up rework. Cutting door openings and precision located flue-ways were done with little effort. The biggest challenge in cutting came when the 5/8 in. stainless grading had to be sized for shelving. The grating would later become the surface for 3 sliding shelves.
Once all the steel was cut to size, fabrication began. For this we chose the MultiMaster® 260, multiprocessing power supplier with it’s integrated wire feeder. Later, as I began to discover, this became the most universal tool used in this fabrication project.
Cutting, fitting, welding and grinding took a ‘first rate team’. For this I called on some of our talented people that included Bob Rebert, Jerry Doherty, Jerry Mathison, Jeff Roscoe, Chris Cline and others for which I am equally thankful. Fabrication took several weeks to complete.
Metal such as this is not difficult to work with but having a vision an understanding of how so many pieces of plate, angle and meshing came together excited me. Although a bit of bruit force was occasionally needed to keep the many pieces aligned the team assembled willingly accepted the challenge.
The joining of all carbon steel was done with Spoolarc 87 (ER70S-7). The higher manganese and silicon content of the wire made the clean-up easier and provided a good cosmetic finish. The performance of the wire and the ease of use made this easier than expected. The versatility of the MIG process along with its mechanical properties proved sufficient for this project. Welding was done in all positions, including vertical up, down and overhead. In a short time both the flue box as well as the fire box as completely assembled and continuously welded. This 2-part construction proved to be a wise choice when it came to moving the entire unit to its final location.
During the fabrication both carbon and stainless was welded to itself as well as to each other. In all, the GMAW, SMAW, GTAW processes were utilized. Stainless mesh grates measuring 5/8 in. round were plasma cut and fitted to carbon steel ¼ in. x ¼ in. angle iron. Each rectangular shaped shelf frame measured 27 in. x 22 in. x ¼ in. All stainless steel mesh grates was attached to the angle iron frame with Arcaloy 309L-16 3/32 in. electrode. All other stainless welding was done with GTAW process of a similar analysis.
In addition to the main structure, other assorted weldments were necessary, those included the sliding shelf supports and door stops. Attachment brackets on opposite sides of the flue were used to support a 2 in. round stainless rod. This will serve the purpose of hanging meat inside the smoker. Individual meat hanger hooks were formed from 5 mm nickel steel rod. In addition, a propane line feeds gas to a cast iron burner attached below the bottom sliding shelf.
Transporting this 500 lb, 2-piece unit could not have been possible without the help of many strong individuals. Once moved, the next step was to paint the entire outside of the unit. Experience tells me that an air-supplied power sprayer emits an excessive amount of over-spray. As a result, I decided to construct a plastic, ceiling to floor curtain, surrounding the smoker unit. After the third coat of black high temperature stove paint was applied I was convinced that the newly pained metal could withstand the Pennsylvania weather.
As the time approached to relocate this 500 lb beast, our excitement grew. Once in place, the 2 separate units were attached together. Twelve pre-drilled holes were aligned between the 2 units and connected with bolt fasteners. Connected together, as a single unit, there was no moving this structure once in place.
The smoker resides as the center piece of my newly constructed outdoor kitchen. In a space once designed for a garden this area has now been transformed into an outdoor kitchen. Equipped with running water, 110 V power and shaded wood framed pergala, the entire area is protected from the rain and sun.
The kitchen area was designed to be a working area providing such conveniences as a built-in stainless steel cooler/icebox, stainless lined fryer pit and double set of stainless steel sink drains. All features making this area suitable for a BBQ any time.
A project of this magnitude takes some engineering expertise, adequate man-power, the proper tools and lots of imagination. Without the help of so many friends, my Dad, Charlie and other supporters, a project of this magnitude would not have been possible. ESAB equipment, filler metals and human resources made this task possible.
Whether making beef brisquette, baby back ribs or pork shoulders, this unit is capable of heating with wood, charcoal or with LP. As one observer so accurately put it, “this is a real piece of work”.
What started out as a backyard water garden project quickly changed? The idea of a smoker has both a social benefit as well as nutritional value. As my son, Patrick so adequately stated, "Dad this is awesome". So the next time your in Hanover stop by, your never know what might be smokin'.
Jeff can be reached for questions by email.
